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Carburetor Holders; Piston Rings (on Kz400); Engine Sprocket (on Kz400); Starter Motor (on Kz550) - Kawasaki KZ400 Service Manual

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272 SUPPLEMENT FOR 1980 MODEL
PISTON RINGS (on KZ400)
The pistons on KZ400 use the one-piece type piston
oil rings instead of the separate type piston oil rings.
Refer to the follows when installing the oil rings:
.Install
the oil ring so that the correct side (marked
"T") faces up.
.Turn
the rings so that the opening in the top ring and
oil ring o f each piston faces forward and the opening
in the second ring faces the rear.
Piston Rings (KZ400)
C@9
T o p R i n g
Second R l n g
CARBURETOR HOLDERS
Removal
:
.Remove the fuel tank (Pg. 47).
.Remove the carburetors (Pg. 49).
.Pull
the vacuum hoses o f f the attachments (on US
model).
.Remove
the screws (8)) and remove the carburetor
holders from the cylinder head.
Installation Notes:
1. For US model, install the #1 and # 4 carburetor
holders so that the vacuum hose attachments point
upward and to the inside, and install the k 2 and
+3
carburetor holders so that the attachments point
downward and t o the outside.
A.
#I
Carburetor Holder
B.
#2
Carburetor Holder
Apply a non-permanent locking agent to the mount-
ing screw threads.
Fit the rubber caps onto the carburetor holder attach-
ments. For US model, f i t the rubber caps (2) onto
the 4 2 and
#3
carburetor holder attachments, and
connect the vacuum hoses t o the
#I
and
#4
carbure-
tor holder attachments.
ENGINE SPROCKET (on KZ400)
The drive chain for KZ400 i s not an "endless" type.
Refer .to the follows when removing and installing the
engine sprocket:
Removal :
.Stand the motorcycle up on its center stand.
.Check that the transmission is in neutral.
.Remove the engine sprocket cover (Pg. 69).
.Remove
the engine sprocket holding plate bolts (2),
and remove the plate.
.Remove
the clip from the chain master link using
pliers, and remove the master link.
@Remove the engine sprocket, and free i t from the drive
chain.
Installation Notes:
1. Mount the engine sprocket while meshed with the
drive chain, and install the drive chain master link
and clip. The direction o f the master link clip must
be as shown.
Incorrect installation of the master link
clip can allow it t o catch on an adjacent
part. I f the clip dislodges, the chain could come apart,
and this could result i n rear wheel lockup and loss of
control.
Master Link Clip Installation
Direction o f Chain Rotation
Clip
+
7
2. Tighten the holding plate bolts (2) to 1.0 kg-m (87
in-l bs) o f torque.
STARTER MOTOR (on KZ550)
Disassembly and Assembly Notes:
Refer to Pgs. 74- 75, noting the following:
1 .
The starter motor on KZ550 has the permanent
magnets inside the yoke instead of the field coils.

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This manual is also suitable for:

Kz500Kz550

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